John Deere Tractors 7210R, 7230R, 7250R, 7270R, 7290R, 7310R Repair Service Manual (TM118919)
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Price: US$ 69.00
John Deere Tractors 7210R, 7230R, 7250R, 7270R, 7290R, 7310R Repair Service Manual (TM118919)
tm118919 - 7R Tractors Repair (S. N. 080001—093999) Technical Manual.pdf
Complete Repair Service Technical Manual for John Deere Tractors 7210R, 7230R, 7250R, 7270R, 7290R, 7310R, with all the service information to maintain, repair, and rebuild like professional mechanics.
John Deere 7R RW (S.N. 080001- ) Tractors 7210R, 7230R, 7250R, 7270R, 7290R & 7310R workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,332 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
Dealer Predelivery Information Form
General Information
Safety
General References
Engine
Component Removal and Installation
Engine Repair
Fuel, Air Intake, Exhaust, and Cooling
Diesel Fuel System
Air Intake System
Auxiliary Drive System
Radiator and Coolers
Exhaust System
Electrical
Connectors
Charging Circuit
Starting Circuit
Relays, Fuses, Solenoids, and Switches
Monitoring System
CommandARM™
Implement and Accessory Connectors
Convenience and Accessory
Infinitely Variable Transmission (IVT™)
Component Removal and Installation
Transmission Repair
Assemble Transmission
e23™ Transmission (e23™)
Component Removal and Installation
Transmission Repair
Assemble Transmission
CommandQuad™ Transmission (CQ)
Component Removal and Installation
PowrQuad-Plus™ Module
Range Box
Drive Train
Component Removal and Installation
Hydraulic Pump Drive
Rear Differential and Input Quill
Rear Final Drives
Rear PTO
Front PTO
1100 Series MFWD
Component Removal And Installation
Final Drives
Axle Housing
Differential
1300 Series MFWD
Component Removal And Installation
Final Drives
Axle Housing
Differential
Triple-Link Suspension (TLS™)
Component Removal And Installation
Final Drives
Axle Housing
Differential
Suspension Components
Brakes
Service Brakes
Hydraulic Trailer Brakes
Air Trailer Brakes
Steering
Steering Column
Steering Valves
Steering Cylinders
Hydraulics
Component Removal and Installation
Hydraulic System
Integrated Hydraulic Pump
Hitch Valve, Selective Control Valves, and Couplers
Rear Hitch
Front Hitch
Miscellaneous
Hood and Side Shields
Wagon and Pick-Up Hitch
Cab and Open Operator’s Station
Component Removal and Installation
Heating, Ventilating, and Air Conditioning (HVAC)
ComfortCommand™ Seat
ComfortCommand™ Seat with HCS Plus
ActiveSeat™
Cab Door and Windshield
Cab Suspension
Dealer Tools
Dealer Fabricated Tools
tm118919 - 7R Tractors Repair(S. N. 080001—093999)
Table of Contents
Foreword
Dealer Predelivery Information Form
Section 10: General Information
Group 05A: Safety
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prevent Machine Runaway
Avoid Backover Accidents
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Handling Batteries Safely
Handle Agricultural Chemicals Safely
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Clean Vehicle of Hazardous Pesticides
Service Machines Safely
Stay Clear of Rotating Drivelines
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Wait Before Opening High-Pressure Fuel System
Service Accumulator Systems Safely
Protect Against High Pressure Spray
Service Cooling System Safely
Avoid High-Pressure Fluids
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Handle Starting Fluid Safely
In Case of Fire
Avoid Static Electricity Risk When Refueling
Avoid Hot Exhaust
Clean Exhaust Filter Safely
Prevent Acid Burns
Keep ROPS Installed Properly
Instructional Seat
Use Steps and Handholds Correctly
Service Front-Wheel Drive Tractor Safely
Transport Tractor Safely
Follow Tire Recommendations
Service Tires Safely
Avoid Harmful Asbestos Dust
Practice Safe Maintenance
Use Proper Tools
Construct Dealer-Made Tools Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Install All Guards
Live With Safety
Group 05B: General References
List of References
Trademarks
Sealants and Adhesives Cross-Reference Chart
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Face Seal Fittings Assembly and Installation—All Pressure Applications
Metric Face Seal And O-ring Stud End Fitting Torque Chart—Standard Pressures
Metric Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications
SAE Face Seal and O-ring Stud End Fitting Torque Chart—Standard Pressures
SAE Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications
External Hexagon Port Plug Torque Chart
Prevent Hydraulic System Contamination
Check Oil Lines and Fittings
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems
Identify Zinc-Flake Coated Fasteners
Use Torque Wrench Adapter
Servicing and Connecting Snap to Connect STC™ Fittings
Use Special Wrench
Install Hydraulic Fittings
Selective Catalytic Reduction (SCR) System Overview
Restored Operation Option
Aftertreatment Indicators Overview
Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter
Cleaning Diesel Exhaust Fluid (DEF) Tank
Section 20: Engine
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 20—00
Other Material 20—00
Specifications 20—00
Remove and Install 6.8 L Engine
Remove and Install 9.0 L Engine
Remove and Install Front Frame
Group 05: Engine Repair
List of References
Essential, Recommended, and Fabricated Tools 20—05
Specifications 20—05
Repair Engine—Use CTM
Remove and Install 6.8 L Engine Rocker Arm Cover
Remove and Install 9.0 L Engine Rocker Arm Cover
Replace Torsional Damper
Section 30: Fuel, Air Intake, Exhaust, and Cooling
Group 05: Diesel Fuel System
List of References
Specifications 30—05
Remove and Install Left-Hand Fuel Tank
Remove and Install Right-Hand Fuel Tank
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System
Group 10: Air Intake System
List of References
Specifications 30—10
Air Intake Pipe Connections
Remove and Install Intake Housing
Remove and Install Aspirator Hose
Remove and Install Charge Air Cooler Pipes—6.8 L
Remove and Install Charge Air Cooler Pipes—9.0 L
Group 15: Auxiliary Drive System
List of References
Essential, Recommended, and Fabricated Tools 30—15
Other Material 30—15
Specifications 30—15
Remove and Install Fan Belt
Inspect Belt Tensioner
Replace Idler Pulleys and Belt Tensioner
Remove and Install Electronic Fan Drive
Replace Fan Drive Pulley
Group 20: Radiator and Coolers
List of References
Essential, Recommended, and Fabricated Tools 30—20
Other Material 30—20
Specifications 30—20
Draining, Flushing, and Refilling Cooling System
Test Radiator and Deaeration Tank
Test Radiator Cap
Remove and Install Deaeration Tank
Remove and Install Cooling Package
Remove and Install Charge Air Cooler
Remove and Install Radiator
Remove and Install Fuel Cooler
Remove and Install Air Conditioning Condenser
Remove and Install Hydraulic Oil Cooler
Leak Test Hydraulic Oil Cooler
Group 25: Exhaust System
List of References
Other Material 30—25
Specifications 30—25
Service Exhaust System
Replace NOx Sensor
Remove and Install DEF Tank
Replace Header Assembly
Replace DEF Dosing Unit
Replace DEF Dosing Injector
Section 40: Electrical
Group 05: Connectors
List of References
Essential, Recommended, and Fabricated Tools 40—05
Other Material 40—05
Use Electrical Insulating Compound
Using High-Pressure Washers
Installation of Repair Wire Assembly (RWA)
Repair AMP™ Connector
Repair AMPSEAL 16™ Connectors
Bosch™ Connectors
Remove Connector Body from Blade Terminals
CINCH™ Control Unit Connectors
Exploded View—CINCH™ FlexBox Connectors
CINCH™ FlexBox Connectors
Repair CPC™ Blade Type Connectors
Repair CPC™, Large Mate-N-Loc™, and Metrimate™ Pin Type Connectors
Repair DEUTSCH™ Connectors
Repair DEUTSCH™ Implement Connectors
Repair ITT Connector
Repair Small Mate-N-Loc™ Socket Connector
Repair Small Mate-N-Loc™ Pin Connector
Repair (Pull Type) Metri-Pack™ Connectors
Repair (Push Type) Metri-Pack™ Connectors
Repair Molex™ Control Unit Connectors
Repair Molex™ Connector
Repair SUMITOMO™ Connectors
Repair Tyco™ Fuel Injector Connector
Repair WEATHER PACK™ Connector
Repair YAZAKI™ Connectors
Group 10: Charging Circuit
List of References
Specifications 40—10
Repair Alternator—Use CTM
Remove and Install Alternator
Replace Alternator Master Fuse
Group 15: Starting Circuit
List of References
Essential, Recommended, and Fabricated Tools 40—15
Specifications 40—15
Repair Starter—Use CTM
Remove and Install Starter Motor
Replace Starter Circuit Relay
Replace Master Fuse
Group 20: Relays, Fuses, Solenoids, and Switches
List of References
Specifications 40—20
General Repair Procedures 40—20
Remove and Install Backup Pump Master Fuse
Remove and Install Backup Pump Relay
Replace Cab Door Light Switch
Replace Seat Raise and Lower Switch
Replace Seat Firmness Switch—ActiveSeat™
Replace Heated Seat Switch
Replace Operator Presence Seat Switch
Replace Start Aid Switch
Replace Ignition Key Switch
Replace Key Immobilizer
Replace Differential Lock Switch
Replace Differential Lock and Rear PTO Solenoids
Replace Hitch Position Potentiometer Assembly
Replace Clutch Pedal Position Sensor
Replace Ethernet Switch
Replace Battery Disconnect Switch
Replace External Hitch Raise-Lower Switches
Replace Air Conditioning Dual Pressure Sensor
Replace Air Conditioning Temperature Sensor
Replace Air Conditioning Motor Speed Control
Replace Starting Aid Solenoid
Group 25: Monitoring System
List of References
Essential, Recommended, and Fabricated Tools 40—25
Other Material 40—25
Specifications 40—25
General Information 40—25
Replace Control Units
Replace Navigation Bar
Replace Engine Coolant Temperature Sensor
Replace Engine Coolant Level Sensor
Replace Air Filter Restriction Indicator Sensor
Replace Fuel Level Sensor
Replace Foot Throttle Sensor
Replace Hydraulic Oil Filter Restriction Sensor
Remove and Install CommandQuad™ Transmission Sensors
Remove and Install IVT™ Transmission Sensors
Remove and Install e23™ Transmission Sensors
Replace Draft Sensing Sensor
Adjust Draft Link Sensor
Replace Rear PTO Speed Sensor
Replace Power Assisted PTO Shift Electromagnets
Replace Radar Sensor—CommandQuad™ Transmissions
Replace Radar Sensor—IVT™ and e23™ Transmissions
Remove and Install MFWD Speed Sensor
Replace Wheel Angle Sensor
Replace Steering Column Module
Replace Steering Input Device
Replace Gyroscope Sensor
Replace CommandCenter™ Processor
Group 30: CommandARM™
List of References
Specifications 40—30
Armrest Test Procedures
Remove and Install CommandARM™ Assembly
Replace Armrest Interface Control Unit (AIC)
Replace Throttle Control Module
Replace Transmission Control Lever Module
Replace SCV Control Lever Module
Replace Rear Hitch Control Lever and SCV I Control Lever Module
Replace Hitch Controls Module
Replace Rear PTO Switch
Replace Front PTO Switch
Replace Secondary Brake Switch
Replace Cab Controls Module
Replace SCV Lock Module
Replace Joystick Module
Group 35: Implement and Accessory Connectors
List of References
Specifications 40—35
Replace Seven-Terminal Outlet Socket
Replace GreenStar™ Terminal Connector
Replace Auxiliary Power Strip
Replace Three-Pin Accessory Outlet
Replace Three-Pin Accessory Outlet—Storage Box
Replace and Adjust Field Lights
Group 40: Convenience and Accessory
List of References
Specifications 40—40
Replace Wiper Motor
Replace Windshield Washer Pumps
Replace Circulation Blower Motor
Replace HVAC Pressurizer Blower Motor
Replace Air Flow Mode Motor
Test Ground-Fault Circuit Interrupter
Replace Hydraulic Charge Pump Pressure Sensor
Remove Radio and Speakers
Replace Refrigerator
Replace Refrigerator Tray
Replace Refrigerator Top Cover
Replace Refrigerator Door
Replace Refrigerator Thermostat
Replace Refrigerator Module
Section 50A: Infinitely Variable Transmission (IVT™)
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 50A—00
Other Material 50A—00
Specifications 50A—00
Remove Transmission—IVT™
Install Transmission—IVT™
Group 05: Transmission Repair
List of References
Essential, Recommended, and Fabricated Tools 50A—05
Other Material 50A—05
Specifications 50A—05
General Repair Procedures 50A—05
Hydrostatic Module Replacement—IVT™
Separate Transmission Housings—IVT™
Install Transmission Front Housing in Repair Stand—IVT™
Install Transmission Rear Housing in Repair Stand—IVT™
Disassemble IVT Transmission—IVT™
Exploded View—Front Valve Housing—IVT™
Repair Front Valve Housing—IVT™
Exploded View—Rear Valve Housing—IVT™
Repair Rear Valve Housing—IVT™
Exploded View—Hydrostatic Gear Train—IVT™
Repair Hydrostatic Gear Train—IVT™
Repair Hydrostatic Cam
Cross Sectional View—Synchronizer—IVT™
Repair Synchronizer—IVT™
Clutch Cover Plate Orientation—IVT™
Cross Sectional View—Mode 2/Mode 3 Clutch Assembly—IVT™
Repair Mode 3 Clutch Assembly—IVT™
Cross Sectional View—MFWD Clutch—IVT™
Repair MFWD Clutch—IVT™
Cross Sectional View—Park Brake—IVT™
Repair Park Brake—IVT™
Repair Reverse Idler—IVT™
Cross Sectional View—Mode 1 Clutch—IVT™
Repair Mode 1 Clutch—IVT™
Cross Sectional View—SU Idler—IVT™
Repair SU Idler—IVT™
Exploded View—Input Planetary—IVT™
Cross Sectional View—Input Planetary—IVT™
Repair Input Planetary—IVT™
Repair Mode 2 Clutch—IVT™
Repair Mode 2 Shaft—IVT™
Repair Differential Drive Shaft—IVT™
Repair Accumulator—IVT™
Group 10: Assemble Transmission
List of References
Essential, Recommended, and Fabricated Tools 50A—10
Other Material 50A—10
Specifications 50A—10
Install Hydrostatic Module—IVT™
Install Front Valve Housing—IVT™
Install Bearing Cups in Rear Housing—IVT™
Install Output Shaft Assembly—IVT™
Install Mode 1 Clutch Assembly—IVT™
Install Mode 3 Clutch Assembly—IVT™
Install Park Brake—IVT™
Install Reverse Shaft Assemblies—IVT™
Install Synchronizer Assembly—IVT™
Install MFWD Clutch Assembly—IVT™
Install Bearing Support and Adjust Bearings—IVT™
Assemble Transmission Housings—IVT™
Install Rear Valve Housing—IVT™
Install Sensors—IVT™
Section 50B: e23™ Transmission (e23™)
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 50B—00
Other Material 50B—00
Specifications 50B—00
Remove Transmission—e23™
Install Transmission—e23™
Group 05: Transmission Repair
List of References
Essential, Recommended, and Fabricated Tools 50B—05
Other Material 50B—05
Specifications 50B—05
General Repair Procedures 50B—05
Cleaning Procedures—Manifold, Rear Cover, and Valves—e23™
Install Transmission Into Repair Position—e23™
Disassemble Transmission—Rear Housing—e23™
Service Shaft Orifices—e23™
Shaft Snap Ring and Thrust Washer Orientation—e23™
Remove and Install Front Manifold Valve (Left—Hand Side)—e23™
Repair Front Manifold Valve (Left—Hand Side)—e23™
Remove and Install Rear Manifold Valve (Right—Hand Side)—e23™
Repair Rear Manifold Valve (Right—Hand Side)—e23™
Cross Sectional View—MFWD Clutch—e23™
Repair MFWD Clutch—e23™
Cross-Sectional View—Transmission Range Input Shaft Assembly—e23™
Repair Transmission Range Input Clutch—e23™
Cross-Sectional View—Transmission Range Output Shaft Assembly—e23™
Repair Transmission Range Output Clutch—e23™
Cross Sectional View—Park Brake—e23™
Repair Park Brake—e23™
Clutch Cover Plate Orientation—e23™
Repair Clutch Pack—e23™
Inspect Clutch Disks—e23™
Disassemble Transmission—Front Housing—e23™
Cross-Sectional View—Transmission Input Shaft Assembly—e23™
Cross-Sectional View—Transmission B Countershaft Assembly—e23™
Cross-Sectional View—Transmission C Countershaft Assembly—e23™
Repair Accumulator—e23™
Group 10: Assemble Transmission
List of References
Essential, Recommended, and Fabricated Tools 50B—10
Other Material 50B—10
Specifications 50B—10
Assemble Transmission—Front Housing—e23™
Assemble Transmission—Rear Housing—e23™
Install Sensors—e23™
Section 50C: CommandQuad™ Transmission (CQ)
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 50C—00
Other Material 50C—00
Specifications 50C—00
Remove Transmission—CQ
Install Transmission—CQ
Remove PowrQuad™—CQ
Install PowrQuad™—CQ
Remove Range Box—CQ
Install Range Box—CQ
Remove MFWD Clutch—CQ
Install MFWD Clutch—CQ
Group 05: PowrQuad-Plus™ Module
List of References
Essential, Recommended, and Fabricated Tools 50C—05
Other Material 50C—05
Specifications 50C—05
Remove, Recondition, and Install Transmission Boost Valve—CQ
Remove, Recondition, and Install Cooler Bypass Valve—CQ
Remove And Install Front Transmission Cover Valves—CQ
Remove, Recondition, and Install Shift Valve Housing—CQ
Remove, Recondition, and Install Transmission Front Cover—CQ
Exploded View—Transmission Oil Pump—CQ
Remove, Recondition, and Install Transmission Oil Pump—CQ
Exploded View—Planetary Drive—CQ
Remove, Recondition, and Install Gear-Shift Planetary Drive—CQ
Remove, Recondition, and Install B1, B2 Brakes—CQ
Remove, Recondition, and Install B3 Brakes—CQ
Exploded View—C4 Clutch—CQ
Remove, Recondition, and Install C4 Clutch—CQ
Exploded View—Reverse Brake—CQ
Remove, Recondition, and Install Reverse Brake—CQ
Exploded View—Forward Clutch with Planetary Drive—CQ
Cross Sectional View—Forward Clutch with Planetary Drive—CQ
Remove, Recondition, and Install Forward Clutch With Planetary Drive—CQ
Exploded View—Output Shaft—CQ
Replace Output Shaft—CQ
Group 10: Range Box
List of References
Essential, Recommended, and Fabricated Tools 50C—10
Other Material 50C—10
Specifications 50C—10
Install Range Box In Repair Stand—CQ
Disassemble Range Box—CQ
Repair MFWD Clutch—CQ
Repair Park Brake—CQ
Repair Rear Cover—CQ
Exploded View—Input Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph)—CQ
Repair Input Shaft—CQ
Exploded View—Output Shaft 40 km/h (25 mph) ECO and 50 km/h (31mph)—CQ
Repair Output Shaft—CQ
Exploded View—Valve Assembly—CQ
Repair Valve Assembly—CQ
Exploded View—Shift Control Housing—CQ
Repair Shift Control Housing—CQ
Exploded View—Shift Rails—CQ
Repair Shift Rails—CQ
Install Bearing Cups—CQ
Install Input/Output Assembly—CQ
Install Shift Forks—CQ
Install MFWD Clutch Assembly—CQ
Install Rear Cover—CQ
Install Valve Assembly—CQ
Install Sensors—CQ
Section 50D: Drive Train
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 50D—00
Other Material 50D—00
Specifications 50D—00
Sealing Instructions 50D—00
Remove Front PTO Assembly
Install Front PTO Assembly
Remove Differential Case
Install Differential Case
Remove Final Drive
Install Final Drive
Group 05: Hydraulic Pump Drive
List of References
Other Material 50D—05
Specifications 50D—05
Remove and Install Pump Drive Housing
Repair Pump Drive Housing
Group 10: Rear Differential and Input Quill
List of References
Essential, Recommended, and Fabricated Tools 50D—10
Other Material 50D—10
Specifications 50D—10
General Repair Procedures 50D—10
Remove Rear Differential
Disassemble, Inspect, and Assemble Rear Differential
Remove Rear Differential Drive Shaft
Replace Check Valves
Determine Rear Differential Drive Shaft Cone Point Shim Pack
Assemble and Install Rear Differential Drive Shaft
Install Rear Differential
Side Quill Adjustment Information
Measure End Play and Adjust Rear Differential Preload
Adjust Rear Differential Backlash
Remove and Install Brake Piston
Group 15: Rear Final Drives
List of References
Essential, Recommended, and Fabricated Tools 50D—15
Other Material 50D—15
Specifications 50D—15
General Repair Procedures 50D—15
Cross-Sectional View—100 mm Rear Axle Housing And Shaft
Cross-Sectional View—100 mm Planet Pinion Carrier
Cross-Sectional View—110/120 mm Final Drive
Remove Planet Pinion Carrier—100 mm
Remove Planet Pinion Carrier—110/120 mm
Disassemble, Inspect, and Assemble Planet Pinion Carrier—100 mm
Disassemble, Inspect, and Assemble Planet Pinion Carrier—110/120 mm
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Install Axle Housing
Install Planet Pinion Carrier And Check Rolling Drag Torque—100 mm
Install Planet Pinion Carrier And Check Rolling Drag Torque—110/120 mm
Group 20: Rear PTO
List of References
Essential, Recommended, and Fabricated Tools 50D—20
Other Material 50D—20
Specifications 50D—20
General Repair Procedures 50D—20
Cross-Sectional View—PTO Clutch
Remove and Disassemble PTO Clutch
Assemble and Install PTO Clutch
Remove and Disassemble Output Shaft and PTO Shifter
Remove and Disassemble Countershaft
Disassemble and Assemble Shaft Position Rod
Cross-Sectional View—Two-Speed Shiftable PTO Countershaft
Cross-Sectional View—Three-Speed Shiftable PTO Countershaft
Assemble and Install Countershaft
Cross-Sectional View—Single-Speed PTO Output Shaft
Cross-Sectional View—Two-Speed Shiftable PTO Output Shaft
Cross-Sectional View—Three-Speed Shiftable PTO Output Shaft
Exploded View—Shiftable PTO Shifter
Exploded View—Power Assisted PTO Shifter
Recondition Mechanical Shifter
Recondition Power Assisted PTO Shifter
Assemble and Install Output Shaft and PTO Shifter
Replace PTO Output Shaft Oil Seal
Replace PTO Input Shaft Oil Seal
Group 25: Front PTO
List of References
Essential, Recommended, and Fabricated Tools 50D—25
Other Material 50D—25
Specifications 50D—25
General Repair Procedures 50D—25
Remove and Install Front PTO Oil Cooler
Remove and Install Front PTO Pump
Remove and Install Front PTO Hub
Disassemble and Assemble Front PTO Gearcase Housing
Disassemble Front PTO Clutch
Assemble Front PTO Clutch
Replace Front PTO Brake
Remove Front PTO Input Shaft
Install Front PTO Input Shaft
Remove Front PTO Output Shaft
Install Front PTO Output Shaft
Remove and Install Modulating Valve
Repair Pressure Regulating Valve
Repair Oil Cooler Bypass Valve
Repair Lube Relief Valve
Section 50E: 1100 Series MFWD
Group 00: Component Removal And Installation
List of References
Essential, Recommended, and Fabricated Tools 50E—00
Other Material 50E—00
Specifications 50E—00
Sealing Instructions 50E—00
Remove Non-Suspended MFWD Axle—1100 Series
Install Non-Suspended MFWD Axle—1100 Series
Group 05: Final Drives
List of References
Essential, Recommended, and Fabricated Tools 50E—05
Other Material 50E—05
Specifications 50E—05
General Repair Procedures 50E—05
Cross-Sectional View—Planetary Carrier and Wheel Hub—1100 Series
Remove, Recondition, And Install Planetary Carrier And Wheel Hub—1100 Series
Cross-Sectional View—Knuckle Spindle Assembly—1100 Series
Disassemble, Inspect, and Assemble Knuckle Spindle Assembly—1100 Series
Replace Kingpin Bearings and Seals—1100 Series
Determine Kingpin Shim Pack—1100 Series
Group 10: Axle Housing
List of References
Essential, Recommended, and Fabricated Tools 50E—10
Specifications 50E—10
Install MFWD Axle Onto Rollover Stand—1100 Series
Remove And Install Final Drive Assembly—1100 Series
Remove Right-Hand Axle Housing—1100 Series
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—1100 Series
Adjust Backlash—1100 Series
Backlash Shim Pack Example and Worksheet—1100 Series
Install Left-Hand Axle Housing Bearing Cup and Shim Pack—1100 Series
Disassemble Right-Hand Axle Housing and Determine Shim Pack—1100 Series
Preload Shim Pack Example and Worksheet—1100 Series
Install Right-Hand Axle Housing—1100 Series
Replace MFWD Pivot Bushing—1100 Series
Group 15: Differential
List of References
Essential, Recommended, and Fabricated Tools 50E—15
Specifications 50E—15
Cross-Sectional View—Differential Housing—Limited Slip Differential 2.5 Ratio—1100 Series
Cross-Sectional View—Differential Housing—Limited Slip Differential 4.0 Ratio—1100 Series
Repair Limited Slip Differential——1100 Series
Assemble Limited Slip Differential—1100 Series
Cross-Sectional View—Differential Drive Shaft And Input Quill—1100 Series
Remove And Disassemble Differential Drive Shaft—1100 Series
Determine Differential Drive Shaft Cone Point Shim Pack—1100 Series
Assemble And Install Differential Drive Shaft—1100 Series
Section 50F: 1300 Series MFWD
Group 00: Component Removal And Installation
List of References
Essential, Recommended, and Fabricated Tools 50F—00
Other Material 50F—00
Specifications 50F—00
Sealing Instructions 50F—00
Remove Non-Suspended MFWD Axle—1300 Series
Install Non-Suspended MFWD Axle—1300 Series
Group 05: Final Drives
List of References
Essential, Recommended, and Fabricated Tools 50F—05
Other Material 50F—05
Specifications 50F—05
General Repair Procedures—MFWD Axle 50F—05
Cross-Sectional View—Planetary Carrier and Wheel Hub—1300 Series
Remove, Recondition, And Install Planetary Carrier And Wheel Hub—1300 Series
Cross-Sectional View—Knuckle Spindle Assembly—1300 Series
Disassemble, Inspect, and Assemble Knuckle Spindle Assembly—1300 Series
Replace Kingpin Bearings and Seals—1300 Series
Determine Kingpin Shim Pack—1300 Series
Group 10: Axle Housing
List of References
Essential, Recommended, and Fabricated Tools 50F—10
Specifications 50F—10
Install and Remove MFWD Axle To Rollover Stand—1300 Series
Remove And Install Final Drive Assembly—1300 Series
Remove Right-Hand Axle Housing—1300 Series
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—1300 Series
Adjust Backlash—1300 Series
Backlash Shim Pack Example and Worksheet—1300 Series
Install Left-Hand Axle Housing Bearing Cup and Shim Pack—1300 Series
Disassemble Right-Hand Axle Housing and Determine Shim Pack—1300 Series
Preload Shim Pack Example and Worksheet—1300
Install Right-Hand Axle Housing—1300 Series
Replace MFWD Pivot Bushing—1300 Series
Group 15: Differential
List of References
Essential, Recommended, and Fabricated Tools 50F—15
Specifications 50F—15
Cross-Sectional View—Differential Housing—Limited Slip Differential 2.5 Ratio—1300 Series
Cross-Sectional View—Differential Housing—Limited Slip Differential 4.0 Ratio—1300 Series
Repair Limited Slip Differential—1300 Series
Assemble Limited Slip Differential—1300 Series
Cross-Sectional View—Differential Drive Shaft And Input Quill—1300 Series
Remove And Disassemble Differential Drive Shaft—1300 Series
Determine Differential Drive Shaft Cone Point Shim Pack—1300 Series
Assemble And Install Differential Drive Shaft—1300 Series
Section 50G: Triple-Link Suspension (TLS™)
Group 00: Component Removal And Installation
List of References
Essential, Recommended, and Fabricated Tools 50G—00
Other Material 50G—00
Specifications 50G—00
Sealing Instructions 50G—00
Remove Suspended MFWD Axle
Install Suspended MFWD Axle
Group 05: Final Drives
List of References
Essential, Recommended, and Fabricated Tools 50G—05
Other Material 50G—05
Specifications 50G—05
Cross-Sectional View—Planetary Carrier and Wheel Hub Without Brake—TLS™
Cross-Sectional View—Planetary Carrier and Wheel Hub With Brake—TLS™
Remove, Recondition, and Install Planetary Carrier and Wheel Hub Without Brake—TLS™
Remove, Recondition, and Install Planetary Carrier and Wheel Hub With Brake—TLS™
Cross-Sectional View—Knuckle Spindle Assembly—TLS™
Disassemble, Inspect, and Assemble Knuckle Spindle Assembly—TLS™
Replace Kingpin Bearings and Seals—TLS™
Determine Kingpin Shim Pack—TLS™
Group 10: Axle Housing
List of References
Essential, Recommended, and Fabricated Tools 50G—10
Other Material 50G—10
Specifications 50G—10
Install Suspended MFWD Axle Onto Repair Stand
Remove And Install Final Drive Assembly—TLS™
Remove Right-Hand Axle Housing—TLS™
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Limited Slip Differential—TLS™
Disassemble Left-Hand Axle Housing and Determine Bearing Cup Shim Pack—Locking Differential—TLS™
Adjust Backlash—TLS™
Backlash Shim Pack Example and Worksheet—TLS™
Install Left-Hand Axle Housing Bearing Cup and Shim Pack—TLS™
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Limited Slip Differential—TLS™
Disassemble Right-Hand Axle Housing and Determine Shim Pack—Locking Differential—TLS™
Preload Shim Pack Example and Worksheet—TLS™
Install Right-Hand Axle Housing—TLS™
Bearing Support Exploded View—TLS™
Remove and Recondition Bearing Support—TLS™
Group 15: Differential
List of References
Essential, Recommended, and Fabricated Tools 50G—15
Specifications 50G—15
Cross-Sectional View—Differential Housing—Limited Slip Differential (2.5 Ratio)—TLS™
Cross-Sectional View—Differential Housing—Limited Slip Differential (4.0 Ratio)—TLS™
Repair Differential Housing—Limited Slip Differential—TLS™
Assemble Differential—Limited Slip Differential—TLS™
Cross-Sectional View—Differential Housing—Heavy Duty With Hydraulic Differential Lock—TLS™
Repair Differential Housing—With Hydraulic Differential Lock—TLS™
Assemble Differential—With Hydraulic Differential Lock—TLS™
Cross-Sectional View—Differential Drive Shaft and Input Quill—TLS™
Remove and Disassemble Differential Drive Shaft—TLS™
Determine Differential Drive Shaft Cone Point Shim Pack—TLS™
Assemble and Install Differential Drive Shaft—TLS™
Group 20: Suspension Components
List of References
Essential, Recommended, and Fabricated Tools 50G—20
Specifications 50G—20
Hydraulic Control Valve Block—TLS™
Relieve Pressure From MFWD Axle Hydraulic System—TLS™
Replace MFWD Axle Position Sensor—TLS™
Cross-Sectional View—MFWD Axle Cylinder Piston Seals—TLS™
Repair MFWD Axle Cylinder Seals—TLS™
Check and Charge Accumulators—TLS™
Section 60A: Brakes
Group 05: Service Brakes
List of References
Essential, Recommended, and Fabricated Tools 60A—05
Specifications 60A—05
General Repair Procedures 60A—05
Remove and Install Brake Rods
Remove and Install Brake Valve
Repair Brake Valve—Manual Backup
Repair Brake Valve—Powered Backup
Remove and Install Front Brake Valve
Repair Front Brake Valve
Remove and Install Secondary Brake Valve
Repair Secondary Brake Valve
Remove and Install Brake Control Manifold
Remove and Install Park Brake Release Manifold
Repair Park Brake Release Manifold
Manually Release Park Brake—IVT™
Manually Release Park Brake—CommandQuad™
Manually Release Park Brake—e23™
Bleed MFWD Brakes
Bleed Brakes
Check Brakes
Group 10: Hydraulic Trailer Brakes
List of References
Specifications 60A—10
Hydraulic Trailer Brake Component Location
Remove and Install Hydraulic Trailer Brake Valve
Group 15: Air Trailer Brakes
List of References
Specifications 60A—15
Air Trailer Brake System
Bleed Air from Air Trailer Brake Reservoirs
Remove and Install Air Compressor
Repair Air Compressor
Remove and Install Air Trailer Brake Pre-Brake Valve
Repair Air Trailer Brake Pre-Brake Valve
Remove and Install Air Trailer Brake Park Valve
Remove and Install Air Trailer Brake Valve
Remove and Install Air Trailer Brake Dryer Assembly
Remove and Install Banjo Fittings
Repair Banjo Fittings
Remove and Install Air Trailer Brake Pressure Regulating Valve
Replace Air Trailer Brake Dryer
Replace Air Trailer Brake Breather
Remove and Install Air Trailer Brake Purge Tank
Remove and Install Air Trailer Brake Dryer Reservoir Check Valve
Repair Air Trailer Brake Dryer Reservoir Check Valve
Section 60B: Steering
Group 05: Steering Column
List of References
Specifications 60B—05
Remove and Install Control Support
Repair Steering Column
Repair Steering Column with ActiveCommand Steering (ACS™)
Group 10: Steering Valves
List of References
Specifications 60B—10
General Repair Procedures 60B—10
Remove and Install Steering Valve
Remove and Install AutoTrac™ Valve
Repair AutoTrac™ Valve
Remove and Install ActiveCommand Steering (ACS™) Valve
Repair ActiveCommand Steering (ACS™) Valve
Remove and Install ActiveCommand Steering (ACS™) Return Circuit Relief Valve
Repair ActiveCommand Steering (ACS™) Return Circuit Relief Valve
Remove and Install Priority Valve Housing
Remove and Install Backup Manifold
Repair Backup Manifold
Remove and Install Backup Pump
Bleed Steering System
Group 15: Steering Cylinders
List of References
Remove and Install Steering Cylinder—MFWD
Repair Steering Cylinder
Group 20: Steering Tie Rod Assembly
List of References
Specifications 60B—20
Remove and Install Steering Tie Rod Assembly
Repair Steering Tie Rod Assembly
Section 70: Hydraulics
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 70—00
Other Material 70—00
Specifications 70—00
Remove and Install Filter Housing
Remove and Install Integrated Hydraulic Pump
Remove and Install Transmission Pump
Remove and Install Scavenge and Lube Pump
Remove and Install Mid-Stack Valve
Remove and Install Hitch-SCV Valve Stack
Remove and Install Rear Hitch Frame
Remove and Install Front 3-Point Hitch
Group 05: Hydraulic System
List of References
Specifications 70—05
General Repair Procedures 70—05
Drain Hydraulic System
Fill Hydraulic System
Bleed Hydraulic System
Group 10: Integrated Hydraulic Pump
List of References
Specifications 70—10
Other Material 70—10
Remove and Install Hydraulic Compensator Valve
Repair Hydraulic Compensator Valve
Disassemble, Repair, and Assemble Integrated Hydraulic Pump
Group 15: Hitch Valve, Selective Control Valves, and Couplers
List of References
Essential, Recommended, and Fabricated Tools 70—15
Specifications 70—15
Disassemble and Assemble Hitch-SCV Valve Stack
Service Pressure Compensator
Service Pressure Compensating Check Valve
Service Solenoid Pilot Valve
Service Spool Centering Spring Assembly
Service Electronic Control Unit
Test Surge Relief Valve
Service Surge Relief Valve
Service Shuttle Valve
Remove and Install Coupler Housing
Repair Couplers
Remove and Install Motor Return
Remove and Install Motor Return with Power Beyond
Group 20: Rear Hitch
List of References
Essential, Recommended, and Fabricated Tools 70—20
Other Material 70—20
Specifications 70—20
Remove and Install Rear Hitch Lift Cylinders
Disassemble, Inspect, and Assemble Rear Lift Cylinder
Replace Rockshaft Bushings
Repair Draft Sensing
Group 25: Front Hitch
List of References
Other Material 70—25
Specifications 70—25
Exploded View—Front Hitch
Remove and Install Front Hitch Lift Cylinders
Repair Front Hitch Lift Cylinder
Section 80: Miscellaneous
Group 05: Hood and Side Shields
List of References
Specifications 80—05
Position Hood Forward
Remove and Install Hood
Remove and Install Grille and Headlight Assembly
Remove and Install Hood Side Panels
Remove and Install Hood Screens
Remove and Install Hood Latch
Group 10: Wagon and Pick-Up Hitch
List of References
Specifications 80—10
Repair Wagon Hitch
Adjust Wagon Hitch Release
Repair Pick-Up Hitch
Adjust Pick-Up Hitch
Section 90: Cab and Open Operator’s Station
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools 90—00
Other Material 90—00
Specifications 90—00
Remove Cab
Install Cab
Repair Cab
Remove Inner Roof
Install Inner Roof
Remove and Install Left Hand Armrest
Group 05: Heating, Ventilating, and Air Conditioning (HVAC)
List of References
Essential, Recommended, and Fabricated Tools 90—05
Other Material 90—05
Specifications 90—05
Repair Air Conditioning System—Use CTM
Hose and Tubing O-ring Connection Torques
Discharge Air Conditioning System
Flushing, Purging, and Evacuating Information
Purge Air Conditioning System
Evacuate Air Conditioning System
Charge Air Conditioning System
Refrigerant Oil Information
Check Compressor Oil Charge
Determine Correct Refrigerant Oil Charge
Add Refrigerant Oil to System
Add Refrigerant Oil to Pressurized System
Remove and Install Compressor
Replace Receiver-Dryer
Remove and Install Expansion Valve
Remove HVAC Module
Install HVAC Module
Remove and Install Heater Control Valve
Group 10: ComfortCommand™ Seat
List of References
Essential, Recommended, and Fabricated Tools 90—10
Other Material 90—10
Specifications 90—10
Remove and Install Seat—ComfortCommand™
Repair Seat Air System—ComfortCommand™
Repair Seat Suspension—ComfortCommand™
Repair Seat Back—ComfortCommand™
Repair Seat Control Knobs—ComfortCommand™
Group 15: ComfortCommand™ Seat with HCS Plus
List of References
Specifications 90—15
Remove and Install Seat—ComfortCommand™ with HCS Plus
Remove and Install Seat Top—ComfortCommand™ with HCS Plus
Repair Seat Back—ComfortCommand™ with HCS Plus
Repair and Install Seat Control Knobs—ComfortCommand™ with HCS Plus
Group 20: ActiveSeat™
List of References
Essential, Recommended, and Fabricated Tools 90—20
Other Material 90—20
Specifications 90—20
Purging Air from ActiveSeat™ System
Remove and Install ActiveSeat™
Remove and Install ActiveSeat™ Actuator
Remove and Install ActiveSeat™ Actuator Hoses
Remove and Install ActiveSeat™ Control Valve Assembly
ActiveSeat™ Hydraulic Control Valve Block
Remove and Install ActiveSeat™ Accumulator
Checking and Charging Replacement Accumulators—ActiveSeat™
Repair ActiveSeat™ Air System
Repair ActiveSeat™ Suspension
Repair ActiveSeat™ Back
Repair ActiveSeat™ Control Knobs
Group 25: Cab Door and Windshield
List of References
Specifications 90—25
Repair Cab Door Latch
Cab Door Adjustment—Step 1
Cab Door Adjustment—Step 2
Cab Door Adjustment—Step 3
Cab Door Adjustment—Step 4
Preparing Windshield Glass or Side Window For Replacement
Group 30: Cab Suspension
List of References
Specifications 90—30
Depressurize Cab Suspension System
Remove and Install Cab Leveling Control Valve
Repair Cab Leveling Valve
Remove and Install Sensor Ball Joint Rod
Adjust Sensor Rod
Remove and Install Position Sensor
Remove and Install Accumulator
Charging Accumulator
Remove and Install Hydraulic Cylinders
Remove and Install Panhard Rod
Bleeding Suspended Cab System
Section 300: Dealer Tools
Group 05: Dealer Fabricated Tools
List of References
Fabricated Tools
DF1057—Axle Adjusting Tool
DFRW4—Axle Wheel Hub Tool
DFRW30A—Axle Jacking Tool
DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
DFRW94—Rear Axle Support Stand
DFRW98—Rear Axle Guide Pin
DFRW132—Differential Side Bevel Gear End Play Tool
DFRW148—ActiveSeat™ Control Valve Holding Tool
DFRW150—SCV-Hitch Valve Stack Lifting Bracket
DFRW178—Front Brake Bleed Wrench
DFRW213—Hydraulic Trailer Brake Test and Bleed Assembly
DFRW219—Wheel Tightening Stand
DFRW235—MFWD Input Shaft Holding Tool
DFRW236—Front PTO Support Bracket
DFRW236A—Front PTO Support Bracket
DFRW237—Differential Drive Shaft Removal Tool
DFRW248—Front PTO Output Shaft Holding Tool
DFRW249—Check Valve Installation Tool
